A composite material structural part forming die compensation method and system

Abstract

The present invention relates to a method and system for compensating a composite structural component mold, and relates to the field of composite structural component molding. The method comprises obtaining a three-dimensional model of the composite structural component and determining a mold surface based on the three-dimensional model; performing a curing deformation simulation on the three-dimensional model according to a curing process curve during the actual molding process to obtain a simulation calculation result; extracting nodes from the mold surface based on the simulation calculation result to obtain the initial coordinates and deformation amounts of all nodes; performing compensation based on the initial coordinates and deformation amounts of all nodes using the mirror compensation principle to obtain a compensated mold surface; and comparing the compensated mold surface with the three-dimensional model to determine the composite structural component mold surface. By combining numerical simulation and mirror compensation, the present invention improves the design cycle of the mold surface and saves molding costs.

Description

Technical Field

[0001] The present invention relates to the field of composite material structure forming, and in particular to a composite material structure forming die compensation method and system. Background Art

[0002] High-performance, precise molding of composite parts is a challenging problem in composite manufacturing. Due to factors such as layup, processing, and tooling, the dimensions of composite parts after molding may deviate from the designed dimensions. This is known as curing distortion. Curing distortion can lead to significant assembly stress, reducing structural strength and fatigue life, and even rendering the part unusable.

[0003] Currently, aerospace companies typically use a trial-and-error approach to control or eliminate the effects of curing deformation during composite molding. This approach, based on operator experience, extensive process testing, and scaled-down part verification, reduces curing deformation by compensating for mold surfaces. This approach relies heavily on the accumulated experience of the process operators, and with the continuous iteration and update of structures, this traditional trial-and-error approach inevitably leads to high molding costs and lengthy design cycles. Summary of the Invention

[0004] The purpose of the present invention is to provide a composite material structural part forming die compensation method and system, which improves the design cycle of the die surface and saves forming costs by combining numerical simulation and mirror compensation.

[0005] To achieve the above object, the present invention provides the following solutions:

[0006] A method for compensating a composite material structural component forming die, comprising:

[0007] Obtaining a three-dimensional model of a composite material structural component and determining a mold surface according to the three-dimensional model;

[0008] Performing a curing deformation simulation on the three-dimensional model according to a curing process curve in an actual molding process to obtain a simulation calculation result;

[0009] Extracting nodes from the mold surface according to the simulation calculation results to obtain initial coordinates and deformation amounts of all nodes;

[0010] Compensation is performed using the mirror compensation principle according to the initial coordinates and deformation amounts of all the nodes to obtain a compensated mold surface;

[0011] The compensating mold profile is compared with the three-dimensional model to determine the composite material structural component mold profile.

[0012] Optionally, performing curing deformation simulation on the three-dimensional model according to the curing process curve in the actual molding process to obtain the simulation calculation result specifically includes:

[0013] According to the curing process curve in the actual molding process, the curing deformation simulation of the three-dimensional model is carried out in ABAQUS software using a sequential coupling method to obtain simulation calculation results.

[0014] Optionally, performing compensation based on the initial coordinates and deformation amounts of all nodes using the mirror compensation principle to obtain a compensated mold surface specifically includes:

[0015] The inverse of the deformation is obtained by using the mirror compensation principle;

[0016] Compensation is performed based on the three-dimensional model, the initial coordinates of all nodes and the inverse deformation amount to obtain a compensated mold surface.

[0017] Optionally, comparing the compensating mold surface with the three-dimensional model to determine the composite material structural component mold surface specifically includes:

[0018] Performing a curing deformation simulation of a composite material structural component according to the compensation mold profile to obtain a compensation simulation model;

[0019] Determining whether a deviation between the simulation compensation model and the three-dimensional model does not exceed a set value, and obtaining a determination result;

[0020] If the judgment result is yes, determining that the compensation mold surface corresponding to the simulation compensation model is a composite material structural component mold surface;

[0021] If the judgment result is no, the mold surface corresponding to the three-dimensional model is updated using the mold surface corresponding to the simulation compensation model, and the process returns to the step of "simulating the curing deformation of the three-dimensional model according to the curing process curve in the actual molding process to obtain the simulation calculation results."

[0022] A composite material structural component forming die compensation system, comprising:

[0023] A model creation module, configured to obtain a three-dimensional model of a composite material structural component and determine a mold profile based on the three-dimensional model;

[0024] A simulation calculation module is used to perform a curing deformation simulation on the three-dimensional model according to a curing process curve in an actual molding process to obtain a simulation calculation result;

[0025] A post-processing module is used to extract nodes from the mold surface according to the simulation calculation results to obtain the initial coordinates and deformation of all nodes;

[0026] A compensation mold surface generation module is used to perform compensation based on the initial coordinates and deformation amounts of all nodes using the mirror compensation principle to obtain a compensation mold surface;

[0027] The comparison module is used to compare the compensation mold surface with the three-dimensional model to determine the mold surface of the composite material structural component.

[0028] Optionally, the simulation calculation module specifically includes:

[0029] The simulation unit is used to perform curing deformation simulation on the three-dimensional model in ABAQUS software using a sequential coupling method according to the curing process curve in the actual molding process to obtain simulation calculation results.

[0030] Optionally, the compensation mold surface generation module specifically includes:

[0031] an inverse deformation amount determining unit, configured to obtain an inverse deformation amount by taking the inverse of the deformation amount using a mirror compensation principle;

[0032] The compensation unit is used to perform compensation according to the three-dimensional model, the initial coordinates of all the nodes and the inverse deformation amount to obtain a compensated mold surface.

[0033] Optionally, the comparison module specifically includes:

[0034] a compensation simulation model generating unit, configured to simulate the curing deformation of the composite material structural component according to the compensation mold profile to obtain a compensation simulation model;

[0035] a judgment unit, configured to judge whether a deviation between the simulation compensation model and the three-dimensional model does not exceed a set value, and obtain a judgment result;

[0036] a composite material structural component mold surface determining unit, configured to determine, if the judgment result is yes, that the compensation mold surface corresponding to the simulation compensation model is the composite material structural component mold surface;

[0037] The returning unit is used to return to the simulation calculation module if the judgment result is no.

[0038] According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0039] The present invention obtains a three-dimensional model of a composite structural component and determines a mold surface based on the three-dimensional model; performs a curing deformation simulation on the three-dimensional model according to the curing process curve during the actual molding process to obtain a simulation calculation result; extracts nodes from the mold surface based on the simulation calculation result to obtain the initial coordinates and deformation amounts of all nodes; compensates based on the initial coordinates and deformation amounts of all nodes using the mirror compensation principle to obtain a compensated mold surface; and compares the compensated mold surface with the three-dimensional model to determine the mold surface of the composite structural component. The present invention preliminarily determines the compensated mold surface of the composite structural component by combining numerical calculation with mirror deformation, significantly shortening the design cycle and saving molding costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0041] Figure 1 A flow chart of the compensation method for a composite material structural component forming die provided by the present invention;

[0042] Figure 2 A schematic flow chart of the method for compensating a composite material structural component forming die provided by the present invention;

[0043] Figure 3 A schematic diagram of the curing deformation simulation results provided by the present invention;

[0044] Figure 4 This is a schematic diagram of the mold compensation effect;

[0045] Figure 5 This is a schematic diagram of the compensation system for the composite material structural component forming die provided by the present invention. DETAILED DESCRIPTION

[0046] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0047] The purpose of the present invention is to provide a composite material structural part forming die compensation method and system, which improves the design cycle of the die surface and saves forming costs by combining numerical simulation and mirror compensation.

[0048] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0049] like Figure 1 and Figure 2 As shown, the present invention provides a compensation method for a composite material structural part forming die, comprising:

[0050] Step 101: Obtain a three-dimensional model of a composite material structural component and determine a mold surface according to the three-dimensional model.

[0051] Establish a three-dimensional model of the composite structural part and determine the corresponding mold surface. The specific determination method is: according to the structural characteristics of the part and the actual molding mold, the mold surface of the part is identified as the corresponding mold surface, and the surface compensation is performed based on this surface.

[0052] Step 102: performing a curing deformation simulation on the three-dimensional model according to a curing process curve in an actual molding process to obtain a simulation calculation result.

[0053] Step 102 specifically includes:

[0054] According to the curing process curve in the actual molding process, the curing deformation simulation of the three-dimensional model is carried out in ABAQUS software using a sequential coupling method to obtain simulation calculation results.

[0055] Following the actual curing process curve during the molding process, a sequential coupling method was used in ABAQUS to simulate the curing deformation of the composite structural component. First, the temperature-curing degree distribution of the composite structural component during the curing molding process was simulated based on the actual curing process. Second, the non-uniform stress field distribution during the molding process of the composite structural component was simulated by considering thermal expansion and chemical shrinkage. Finally, the curing deformation of the composite structural component was determined by selecting appropriate stress release points.

[0056] Step 103: extracting nodes from the mold surface according to the simulation calculation results to obtain initial coordinates and deformation amounts of all nodes.

[0057] According to the simulation calculation results, the corresponding node coordinate and deformation extraction code was written in Python in the ABAQUS post-processing result module to obtain the initial coordinates and deformation of the mold surface nodes after curing, and output them as a text file.

[0058] Step 104: Compensation is performed using the mirror compensation principle according to the initial coordinates and deformation amounts of all the nodes to obtain a compensated mold surface.

[0059] Step 104 specifically includes:

[0060] The deformation amount is negated by the mirror compensation principle to obtain an inverse deformation amount, and compensation is performed according to the three-dimensional model, the initial coordinates of all nodes and the inverse deformation amount to obtain a compensated mold surface.

[0061] According to the principle of mirror compensation, the deformation of the mold surface nodes is multiplied by a negative value to obtain the inverse deformation for compensation. The Realistic Shape Optimizer function in CATIA is used to implement the compensation operation. The specific compensation method is: import the initial design surface corresponding to the 3D model in step 101, and input the node coordinates on the surface and the corresponding inverse deformation information to generate the compensated mold surface.

[0062] Step 105: Compare the compensating mold surface with the three-dimensional model to determine the composite material structural component mold surface.

[0063] Step 105 specifically includes:

[0064] The composite material structural component curing deformation simulation is performed according to the compensation mold surface to obtain a compensation simulation model.

[0065] It is determined whether the deviation between the simulation compensation model and the three-dimensional model does not exceed a set value, and a determination result is obtained.

[0066] If the judgment result is yes, it is determined that the compensation mold surface corresponding to the simulation compensation model is the mold surface of the composite material structural part; if the judgment result is no, the mold surface corresponding to the simulation compensation model is used to update the mold surface corresponding to the three-dimensional model and return to the step of "obtaining the simulation calculation result according to the curing process curve in the actual molding process and the curing deformation simulation of the three-dimensional model".

[0067] Based on the generated compensation mold surface, the curing deformation of the composite material structural component under the compensation mold condition is simulated and calculated, and compared with the design component model to determine whether the compensation surface meets the requirements; the specific comparison method is: in Geomagic Qualify software, the initial design surface corresponding to the three-dimensional model in step 101 and the compensation mold surface obtained in step 104 are compared. If the deviation does not meet the requirements, the compensated surface can be redefined as the initial surface, and steps 102, 103, and 104 can be repeated until the deviation meets the requirements.

[0068] After the mold surface of the composite material structural part meets the conditions, the composite material structural part is formed according to the compensation mold surface that meets the requirements.

[0069] This invention uses structural curing deformation simulation and mirroring to generate a compensated mold surface, ensuring that the part formed using the compensated surface meets the desired molding requirements. Finite element simulation allows for a relatively accurate simulation of the curing deformation of composite materials after molding. Compensating for the structural surface based on the simulation results can significantly shorten design cycles and reduce molding costs.

[0070] In this embodiment, the method provided by the present invention is used to compensate the mold surface of a special-shaped composite material structure. The structure ply is [0 / 45 / -45 / 90] 3s .

[0071] According to the geometric model of the part and the actual forming process, its inner surface is determined to be the die-mounting surface of the part. Therefore, the inner surface of the part is used as the compensating molding surface.

[0072] According to the specific molding process of the part, the solidification deformation simulation of the part is carried out. The simulation results are as follows Figure 3 As shown, from Figure 3 It can be seen from the figure that the maximum curing deformation of the part after molding is 6.512mm. The deformation of the part is large. If molding is carried out directly, the molding quality is difficult to guarantee.

[0073] According to the simulation calculation results of solidification deformation, the node coordinate information of all nodes on the inner surface and the corresponding deformation in each direction are extracted and output in text form.

[0074] According to the principle of mirror deformation compensation, the deformation amount in each direction is multiplied by a negative sign, and finally a text file containing the initial coordinate information of the inner surface nodes and the anti-deformation information is obtained, and the corresponding compensation mold surface is generated in the CATIA software.

[0075] Based on the compensated mold surface, the part structure is regenerated and the solidification deformation simulation is performed. The inner surface of the part obtained by the re-simulation result is compared with the inner surface of the designed part in Geomagic Qualify. The comparison results are as follows: Figure 4 As shown, it can be seen that the standard deviation is 0.2812 mm, which is within the allowable deviation range, indicating the effectiveness of the proposed compensation design method.

[0076] The present invention establishes a three-dimensional model of a composite structural component and determines a corresponding mold surface; performs a curing deformation simulation calculation of the composite structural component based on the actual molding process; extracts the initial coordinates and deformation of all nodes on the mold surface based on the simulation calculation results; generates the inverse deformation of the mold surface nodes based on the principle of mirror compensation, and uses this to generate a compensating mold surface; based on the generated compensating mold surface, simulates and calculates the curing deformation of the composite structural component under the compensating mold conditions, compares it with the designed component model, and determines whether the compensating mold surface meets the requirements; and molds the composite structural component using the compensating mold surface that meets the requirements. The present invention preliminarily determines the compensating mold surface of the composite structure by combining numerical calculation with mirror deformation, significantly shortening the design cycle and saving molding costs.

[0077] like Figure 5 As shown, the present invention provides a composite material structural part forming die compensation system, comprising:

[0078] The model creation module 501 is used to obtain a three-dimensional model of a composite material structural component and determine a mold surface according to the three-dimensional model.

[0079] The simulation calculation module 502 is used to perform a curing deformation simulation on the three-dimensional model according to the curing process curve in the actual molding process to obtain a simulation calculation result.

[0080] The simulation calculation module 502 specifically includes:

[0081] The simulation unit is used to perform curing deformation simulation on the three-dimensional model in ABAQUS software using a sequential coupling method according to the curing process curve in the actual molding process to obtain simulation calculation results.

[0082] The post-processing module 503 is used to extract nodes from the mold surface according to the simulation calculation results to obtain the initial coordinates and deformation amounts of all nodes.

[0083] The compensation mold surface generating module 504 is used to perform compensation based on the initial coordinates and deformation amounts of all the nodes using the mirror compensation principle to obtain the compensation mold surface.

[0084] The compensation mold surface generation module 504 specifically includes:

[0085] The inverse deformation determination unit is used to take the inverse of the deformation amount by using the mirror compensation principle to obtain the inverse deformation amount; the compensation unit is used to compensate according to the three-dimensional model, the initial coordinates of all the nodes and the inverse deformation amount to obtain the compensated mold surface.

[0086] The comparison module 505 is used to compare the compensation mold surface with the three-dimensional model to determine the composite material structural component mold surface.

[0087] The comparison module 505 specifically includes:

[0088] a compensation simulation model generating unit, configured to simulate the curing deformation of a composite material structural part according to the compensation mold profile, and obtain a compensation simulation model; a judging unit, configured to judge whether the deviation between the simulation compensation model and the three-dimensional model does not exceed a set value, and obtain a judgment result; a composite material structural part mold profile determining unit, configured to determine that the compensation mold profile corresponding to the simulation compensation model is a composite material structural part mold profile if the judgment result is yes; and a returning unit, configured to return to the simulation calculation module if the judgment result is no.

[0089] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Reference can be made to the common and similar parts between the various embodiments. For the systems disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple, and the relevant parts can be referred to the method description.

[0090] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the method and core concept of the present invention. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the present invention. In summary, the contents of this specification should not be construed as limiting the present invention.

Claims

1. A method for compensating a composite material structural part forming die, characterized in that: include: Obtaining a three-dimensional model of a composite material structural component and determining a mold surface according to the three-dimensional model; Performing a curing deformation simulation on the three-dimensional model according to a curing process curve in an actual molding process to obtain a simulation calculation result; Extracting nodes from the mold surface according to the simulation calculation results to obtain initial coordinates and deformation amounts of all nodes; Compensation is performed using the mirror compensation principle according to the initial coordinates and deformation amounts of all the nodes to obtain a compensated mold surface; The compensating according to the initial coordinates and deformation of all the nodes using the mirror compensation principle to obtain a compensated mold surface specifically includes: taking the inverse of the deformation using the mirror compensation principle to obtain an inverse deformation; compensating according to the three-dimensional model, the initial coordinates of all the nodes, and the inverse deformation to obtain a compensated mold surface; The compensation mold surface is compared with the three-dimensional model to determine the mold surface of the composite material structural part; the comparison of the compensation mold surface with the three-dimensional model to determine the mold surface of the composite material structural part specifically includes: performing a curing deformation simulation of the composite material structural part according to the compensation mold surface to obtain a compensation simulation model; judging whether the deviation between the simulation compensation model and the three-dimensional model does not exceed a set value to obtain a judgment result; if the judgment result is yes, determining that the compensation mold surface corresponding to the simulation compensation model is the mold surface of the composite material structural part; if the judgment result is no, using the mold surface corresponding to the simulation compensation model to update the mold surface corresponding to the three-dimensional model, and returning to the step of "performing a curing deformation simulation on the three-dimensional model according to the curing process curve in the actual molding process to obtain a simulation calculation result".

2. The method for compensating a composite material structural component forming die according to claim 1, wherein: The curing deformation simulation of the three-dimensional model is performed according to the curing process curve in the actual molding process to obtain the simulation calculation results, specifically including: According to the curing process curve in the actual molding process, the curing deformation simulation of the three-dimensional model is carried out in ABAQUS software using a sequential coupling method to obtain simulation calculation results.

3. A composite material structural part forming die compensation system, characterized in that: The composite material structural component forming die compensation system applies the composite material structural component forming die compensation method according to any one of claims 1 to 2, and the system comprises: A model creation module, configured to obtain a three-dimensional model of a composite material structural component and determine a mold profile based on the three-dimensional model; A simulation calculation module is used to perform a curing deformation simulation on the three-dimensional model according to a curing process curve in an actual molding process to obtain a simulation calculation result; A post-processing module is used to extract nodes from the mold surface according to the simulation calculation results to obtain the initial coordinates and deformation of all nodes; A compensation mold surface generation module is used to perform compensation based on the initial coordinates and deformation amounts of all nodes using the mirror compensation principle to obtain a compensation mold surface; The comparison module is used to compare the compensation mold surface with the three-dimensional model to determine the mold surface of the composite material structural component.

4. The composite material structural component forming die compensation system according to claim 3, characterized in that: The simulation calculation module specifically includes: The simulation unit is used to perform curing deformation simulation on the three-dimensional model in ABAQUS software using a sequential coupling method according to the curing process curve in the actual molding process to obtain simulation calculation results.

5. The composite material structural component forming die compensation system according to claim 3, characterized in that: The compensation mold surface generation module specifically includes: an inverse deformation amount determining unit, configured to obtain an inverse deformation amount by taking the inverse of the deformation amount using a mirror compensation principle; The compensation unit is used to perform compensation according to the three-dimensional model, the initial coordinates of all the nodes and the inverse deformation amount to obtain a compensated mold surface.

6. The composite material structural component forming die compensation system according to claim 3, characterized in that: The comparison module specifically includes: a compensation simulation model generating unit, configured to simulate the curing deformation of the composite material structural component according to the compensation mold profile to obtain a compensation simulation model; a judgment unit, configured to judge whether a deviation between the simulation compensation model and the three-dimensional model does not exceed a set value, and obtain a judgment result; a composite material structural component mold surface determining unit, configured to determine, if the judgment result is yes, that the compensation mold surface corresponding to the simulation compensation model is the composite material structural component mold surface; The returning unit is used to return to the simulation calculation module if the judgment result is no.

Images